ERS Electronics Hardware Designer

GM Performance Power Units – Concord, NC

Title:

ERS Electronics Hardware Designer

Drive the future of Formula 1 hybrid technology with GM PPU! We're seeking a skilled ERS Electronics Hardware Designer to craft high-performance hardware for our Energy Recovery System (ERS) electronics in Concord, NC. In this critical hands‑on role, you'll specialize in PCB layout, routing, optimization, simulation, and testing for power electronics like CU-K inverters, DC-DC converters, power distribution modules, sensors, and control interfaces, ensuring they thrive under extreme race conditions while meeting FIA F1 standards.

• Develop detailed PCB layouts using tools like Altium Designer for ERS components, including high‑voltage inverters (CU-K), DC‑DC converters, power distribution boards, sensor interfaces, and gate drivers, focusing on signal integrity, thermal management, radiated/conducted emissions, and minimal mass.
• Collaborate with ERS Electronics Lead, power electronics engineers, firmware teams, and mechanical/thermal designers to integrate hardware designs into the hybrid power unit, optimizing for efficiency, EMI/EMC compliance, high‑voltage safety, and compact packaging.
• Perform design simulations (e.g., LTSpice, thermal modeling), generate Gerber files and fabrication packages, conduct design rule checks (DRC), and lead prototyping, rig testing (EMC, high‑voltage cycling, vibration), and track validation to deliver race‑proven boards.
• Preform electrical simulations
• Lead a full PCB development process. Starting with layout requirements and design rule formatting to symbol and footprint creation, taking that all into complex multi‑layer layouts to then generate Gerber templates and other manifesting files.
• Execute and oversee hardware testing including EMC compliance, thermal cycling, high‑voltage stress tests, and dyno validation; debug prototypes, analyze failures via oscilloscopes/spectrum analyzers, and iterate designs for reliability under FIA ERS limits.
• Conduct design reviews, FMEA risk assessments, and ensure adherence to IPC standards, FIA regulations for ERS power limits, and PLM processes in Teamcenter.

• Bachelor's in Electrical/Electronics Engineering or related field, with 3+ years in PCB layout, hardware design, and testing for high‑reliability power electronics, preferably in motor sport, hybrids, or aerospace.
• Advanced proficiency in Altium Designer (required), experience with high‑speed/high‑voltage/high‑power PCB design, stack‑up optimization, controlled impedance routing, simulation tools (LTSpice), and test equipment (oscilloscopes, spectrum analyzers).
• Strong knowledge of wide‑bandgap semiconductors, EMI/EMC mitigation, HV safety protocols, F1 hybrid regs, and testing methodologies; familiarity with harness integration and automated manufacturing.
• Experience in designing at minimum 4 layer PCB boards and ranging all the way to flexible circuit boards with EMC and EMI considerations to optimize for packaging and mass.
• Familiarity with creating and managing component libraries. Creating request pipelines and managing assignment. Ranging from passives to complex 100+ pin custom components and their respective footprints.
• Experience with IPC standards and practices.
• Experience routing and laying out power electronics components for high power applications. Routing noise sensitive signals such as gate drives and sense lines around semiconductors and magnetics with attention to EMI mitigation and shielding.

• Hands‑on experience in motor sport PCB prototyping, dyno/track testing, failure analysis, and rapid iteration under tight deadlines.
• Expertise in data‑driven optimization, advanced packaging (e.g., embedded passives), quality frameworks, and test automation for high‑pressure environments.
• Proven collaboration in multidisciplinary teams pushing performance limits.

You’ll play a pivotal role in ensuring the reliability and performance of a next‑generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.

Please note:

GM Performance Power Units and all affiliated companies are Equal Opportunity employer(s). Minorities, women, veterans, and individuals with disabilities are encouraged to apply. For more information regarding the EEOC, please visit https://(Use the "Apply for this Job" box below)..

Only direct hires need apply to or inquire about job postings at GM Performance Power Units. We are not accepting calls, resumes or applications from recruiting firms at this time.